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Mitsubishi Evolution X. Manual - part 8

BODY REPAIR

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BASE OF BODY REPAIR

9-29

1. Remove the components near the crack.
2. Make

φ 6 − 8 mm (0.24 − 0.31 inch) holes (to prevent further

cracking), by using a drill, at points 7

− 8 mm (0.28 − 0.31

inch) from the crack ends.

3. Use a

φ 10 − 12 mm (0.39 − 0.47 inch) drill to bevel the hole

openings.

4. Use a chisel or gouging tool to open up the crack and holes,

and then fill the crack and holes by MIG welding.

CAUTION

• Gas welding should be avoided because it causes ther-

mal distortion of the frame.

• When using a grinder for finishing, be careful not to

grind the frame excessively.

5. Using a grinder for finishing after welding.

CAUTION

• The reinforcement plate should completely cover the

cracked part.

• The reinforcement plate should be the same thickness

and material as the frame.

6. To avoid a concentration of stress, prepare a reinforcement

plate that has been cut to 30

− 45 degree angle at both

ends.

AB301469

Crack-stop hole

Crack

Ø6 – 8 mm
(0.24 – 0.31 in)

A : 7 – 8 mm (0.28 – 0.31 in)

AB301470AB

Ø10 – 12 mm
(0.39 – 0.47 in)

Ø10

–

12 mm

Ø6

–

8 mm

AB301470 AC

(0.24

–

0.31 in)

(0.39

–

0.47 in)

AB301471AD

Crack

Crack-stop
hole

Approx.
8 mm
(0.31 in)

Approx.
1 mm
(0.04 in)

Approx.

90˚

If a chisel
is used

If a gouge
is used

AB200131AB

AB301461

A : 30 – 45˚

BODY REPAIR

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CAUTION

Be sure that the edges of the reinforcement plate are not
near any place where a concentration of stress of the
crossmember or spring hanger installation part, etc. could
easily occur.
7. Attach the reinforcement plate to the repaired crack area by

MIG welding. In order to avoid a concentration of stress at
the time, weld the reinforcement plate at points about 10 mm
(0.39 inch) from its edges.

NOTE: If the crack is at the upper side of the frame, attach
the reinforcement plate facing downward, as shown in (1).
If the crack is at the lower side, attach the reinforcement
plate to face upward, as shown in (2).

8. Finally, apply a coating of chassis black to the repaired area

and to any places where the coating has flaked off.

AB200133

10 mm (0.39 in)

Welded point

AB200133

AB200134

AB200134AB

(2)

(1)

BODY REPAIR

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NOTES REGARDING REPAIR WORK

M4090015000039

SAFETY MEASURES

PROTECTIVE GEAR

During body repair work, a work suit, a work cap, and safety
shoes should be worn at all times. Depending on the work
being done, safety glasses, gloves, ear protectors, a dustproof
mask, etc., should also be worn as needed.

1. Safety glasses
2. Work cap
3. Ear protectors
4. Head protector
5. Work suit
6. Dustproof mask
7. Work apron
8. Welding gloves
9. Foot and ankle protectors

10. Safety shoes
11. Work gloves

SUPPLEMENTAL RESTRAINT SYSTEM
(SRS)

1. Items to review when servicing SRS

(1) Be sure to read Service Manual GROUP 52B,

Supplemental Restraint System (SRS). For
safe operation, please follow the directions
and heed all warnings.

(2) Wait at least 60 seconds after disconnecting

the battery cable before doing any further
work. The SRS system is designed to retain
enough voltage to deploy the air bag even
after the battery has been disconnected.
Serious injury may result from unintended air
bag deployment if work is done on the SRS
system immediately after the battery cable is
disconnected.

(3) Warning labels must be heeded when

servicing or handling SRS components.

(4) Always use the designated special tools and

test equipment.

(5) Store components removed from the SRS in a

clean and dry place. The air bag module
should be stored on a flat surface and placed
so that the pad surface is facing upward.

(6) Never attempt to disassemble or repair the

SRS components (SRS-ECU, air bag module
and clock spring). If there is a defect, replace
the defective part.

(7) Whenever you finish servicing the SRS, check

the SRS warning light operation to make sure
that the system functions properly.

(8) Be sure to deploy the air bag before disposing

of the air bag module or disposing of a vehicle
equipped with an air bag.

2. Observe the following when carrying out

operations on places where SRS components are
installed, including operations not directly related
to the SRS air bag.
(1) When removing or installing parts, do not allow

any impact or shock to occur to the SRS
components.

(2) If heat damage may occur during paint work,

remove the SRS-ECU, the air bag module,
clock spring, the front impact sensor, the side
impact sensor, and the seat belt pre-tensioner.

• SRS-ECU, air bag module, clock spring, front

impact sensor, the side impact sensor: 93

°C

(200

°F) or more

• Seat belt pre-tensioner: 90 °C (194 °F) or more

AB200104

BODY REPAIR

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SECURING THE VEHICLE

If the vehicle is raised on a jack, be sure to always support it
with jack stands positioned at the specified points.

CLEARING THE AREA OF FLAMMABLE

MATERIALS

Because of the presence of many various kinds of flammable
materials, organic solvents, etc., in the work area, there is
always the possibility of a fire or explosion. It is, therefore,
important to keep the work area as clear as possible of such
dangerous materials.

HANDLING ELECTRONIC PARTS AND

SEMICONDUCTORS

WARNING

Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.

When the body is used as the ground during welding for body
repairs, be absolutely sure to first disconnect the battery's posi-
tive (+) cable.

CAUTION

• Be sure that both the ignition and lighting switches are

"LOCK" (OFF) position before either disconnecting or
reconnecting a battery cable. (If this is not done, equip-
ment containing semiconductors could be damaged).

• Note that the memory of electronic equipment having a

memory function will be cleared when the battery cable
is disconnected.

NOTE: Vehicles today include a great many electronic parts
and components, and these are in general very susceptible to
adverse effects caused by overcurrent, reverse current, elec-
tromagnetic waves, high temperature, high humidity, impacts,
etc. In particular, such electronic components can be damaged
if there is a large current flow during welding from the body
side, etc.
This is because, for electronic components that incorporate a
back-up circuit (for memory retention) that functions (by a
trickle current) even when the ignition switch is at OFF, an elec-
tronic circuit is formed even when the switch is at OFF.

HANDLING COMBUSTIBLE MATERIALS

If welding work is to be done in the area of the fuel tank, the fuel
tank must be removed to prevent the generation of flammable
gases. Also be sure to cap the inlet port and the pipes of the
fuel tank after removal to prevent the escape of any fuel or
flammable gases.
Wipe up any fuel, oil, etc., spilled in the work area as soon as
possible.
Only the amounts of paint to be used for the day's work should
be in the work area; do not keep excessive amounts of paint, or
paint which is not going to be used, in the work area.

AB200105

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